Internal Gear Hub

ABSTRACT

The invention relates to an internal gear hub for a bicycle includes a rotating cam which locates against a retractable cam follower within a multiple speed internal gear hub. The position of the cam determines which speed is selected. The cam is actuated by reversing the direction of the drive input (pedaling backwards) by a fixed or predetermined amount of rotation. The cam follower is retracted when the drive input is reversed and when the rotation is greater than that required to rotate the cam into the next position. When the cam follower retracts, the cam will return to a default position and will select a default speed.

BACKGROUND OF THE INVENTION

The invention relates to a hub for a pedal-driven vehicle, such as a bicycle. In particular, the invention relates to a shift mechanism with a reset feature, for a multiple speed internal gear hub.

U.S. Pat. No. 3,726,156 describes a three speed internal gear hub, which is constructed so that the speeds are selected through a back pedaling motion. One term for such a hub is a “kickback” hub. The speed selection is determined by the position of a rotating cam with three possible positions, one for each speed. However, in this hub, speed selection is sequential and only proceeds in a predetermined direction; the rider must sequentially cycle through the three positions of the cam until the desired speed is selected. In combination with a coaster (back pedal) brake, this can make the operation complex, as a gear change necessarily occurs each time the brake is activated.

SUMMARY OF THE INVENTION

An object of the invention is to enable the rider to ‘reset’ the shifting mechanism to the initial/easiest (i.e., first) gear when either the brake is activated or with one backpedal motion while the bike is moving or at rest. This overcomes the inconvenience of a sequential shifting system which can result in the rider being in an undesirable gear after using the brake.

The invention provides an internal gear hub for a bicycle with a gear shifting mechanism that includes a rotating cam that locates against a retractable cam follower within a multiple speed internal gear hub. The position of the cam determines which of the multiple speeds is selected. The cam is actuated by reversing the direction of the drive input (pedaling backwards) by a fixed or predetermined amount of rotation. The cam follower is retracted by a reset member and taken out of engagement with the cam when the drive input is reversed and when the rotation is greater by a predetermined amount than that required to rotate the cam into the next forward gear position. When the cam follower is caused to retract, the cam returns to a default or initial position and will select a default or initial speed, i.e., an initial or home state of the hub.

One aspect of the invention provides a hub for a pedal-driven vehicle, including a fixed axle. A planetary gear mechanism is arranged about the fixed axle, the planetary gear mechanism operable to produce an initial gear ratio and at least one other gear ratio. A driver is arranged about the fixed axle and rotatable in a drive direction and a non-drive direction and a shifting mechanism is coupled to the driver, the shifting mechanism including a cam, a reset member, and a cam follower engageable with the cam and the reset member. The cam includes a profile and being axially movable to select between the initial gear ratio and the at least one other gear ratio of the hub, the cam follower configured to engage the profile of the cam to axially position the cam, and the reset member configured to disengage the cam follower from the cam in response to a rotational movement of the driver in the non-drive direction and permit the cam to move axially to reset to the initial gear ratio.

Other aspects of the invention provide a hub of claim wherein the cam may be biased into an initial position that produces the initial gear ratio. The reset member may be configured to permit the cam to reset to the initial position in response to the rotational movement of the driver an amount greater than required to produce a change in gear ratio but less than required to produce braking. The shifting mechanism may be coupled to the driver through a clutch. Both the cam and the reset member may be coupled to the driver through a clutch. The cam may be coupled to the driver through a first clutch and the reset member may be coupled to the driver through a second clutch. The first clutch and the second clutch each may comprise a clutch spring. The profile of the cam may be an indexed profile positioned on an end of the cam. The cam follower may be configured to engage the indexed profile of the cam. The cam follower may be biased to engage the cam. The cam follower may be disposed on the axle. The cam follower may be pivotally received by the axle. The axle may have a recess in which the cam follower is disposed. The cam follower may be biased away from the axle to project from the recess so as to engage the cam. The cam follower may have a face configured to engage the reset member. The reset member may be annular. The reset member may be arranged about the cam follower. The reset member may be configured to engage the face of the cam follower. The reset member may have an interior opening that interiorly receives the cam follower. The interior opening may have an interior surface that defines a first radius and a second radius, the first radius being greater than the second radius. The first radius does not disengage the cam follower and the second radius disengages the cam follower from the cam when the second radius is engaged with the face of the cam follower. The reset member may include an interior face extending between the first radius and the second radius of the interior surface. The interior face of the reset member may be configured to engage with the face of the cam follower. The reset member may be configured to permit the cam to reset to an initial position corresponding to the initial gear ratio in response to the rotational movement of the driver a predetermined amount greater than required to produce a change in gear ratio but less than required to produce braking. The reset member may be configured to permit the cam to reset to an initial position corresponding to the initial gear ratio in response to a backpedaling movement a predetermined amount greater than required to produce a change in gear ratio but less than required to produce braking.

An embodiment of an internal gear hub for a bicycle according to the invention will be described in the following with the use of figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a hub according to an embodiment of the invention;

FIG. 2 is an end view of the hub of FIG. 1;

FIGS. 3 a, 3 b, and 3 c are a longitudinal section of the hub of FIG. 1;

FIGS. 4-10 are cross sections of the hub on lines 4-10 of FIG. 3 b;

FIG. 11 is an exploded view of the hub of FIG. 1;

FIG. 12 is a close up perspective view of the hub axle, the shift cam, shift cam profile, and the cam follower of the hub of FIG. 1;

FIG. 13 is a close up perspective view of the cam follower and the reset member of the hub of FIG. 1;

FIG. 14 is a longitudinal section of the hub of FIG. 1 during the initial part of a reset; and

FIG. 15 is a longitudinal section of the hub of FIG. 1 at the completion of a reset.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

FIGS. 1-15 are directed to a hub 20 according to one embodiment of the invention, around which a wheel can be constructed and which then can be mounted to a frame of a pedal-driven vehicle, such as a bicycle. The hub 20 includes four main sub-assemblies: a hub shell 22 and driver 24, a braking mechanism 26, an epicyclic gearbox 28, which is also known as a planetary gear mechanism, and a shifting mechanism 30 with a reset feature 31.

The hub shell 22 forms the casing of the hub 20. The hub shell 22 is illustrated as being generally cylindrical, and is shaped and sized to house the inner workings of the hub, for example, the braking mechanism 26, the planetary gear mechanism 28, and the shifting mechanism 30, and so on, but it will be understood that the hub shell may be any suitable shape and made from any suitable material, such as steel or aluminum. The hub shell 22 includes spaced spoke flanges 32 that are configured to receive spokes (not shown) for building the hub 20 into a wheel suitable for attaching the hub 20 to the frame (not shown). The hub shell 22 functions to transmit the output torque from the inner workings of the hub 20 to the wheel.

The driver 24 is arranged at one end of the hub shell 22 and includes one or more sprockets 34 for engaging a drive chain of a drive train (not shown) of the vehicle, as is well known. The driver 24 receives input torque, via the sprocket 34, from the drive train and transmits it to the inner workings of the hub 20.

An axle 36 is disposed within the hub shell 22, and is attachable to the frame. The hub shell 22 and driver 24 both rotate independently around the axle 36.

The braking mechanism 26 is a well-known, existing mechanism which is currently used in a number of internal gear hubs, such as those manufactured by SRAM®. The braking mechanism, commonly called a “coaster brake,” is activated by reversing the direction of torque input, which causes the engagement of a set of pawls 38, which may be referred to a “brake pawls,” mounted on the driver 24. The reverse direction will be understood to mean the direction that is opposite the pedaling direction, (see FIG. 2—wherein the pedaling or forward direction is indicated by “D”), which forward/pedaling direction is the direction that the pedals are rotated for moving the vehicle forward. The brake pawls 38 of the braking mechanism 26, which are operably disposed between the driver 24 and the hub shell 22, are configured to engage only in the reverse/braking/counterclockwise direction, as is well known. Operation of the braking mechanism is controlled by a control bushing 108, which at a predetermined position of the driver 24 corresponding to a braking operation, exposes the brake pawls 38 and permits the pawls to engage. It will be understood that forward pedaling motion causes the driver 24 to rotate in a forward direction, and a reverse pedaling motion causes the driver to rotation in a reverse direction.

The planetary gear mechanism 28 is a typical epicyclic gearbox or planetary gear mechanism including a sun gear 40, which may be part of, or attached to, the axle 36. In both alternatives, the sun gear 40 remains rotationally fixed to the axle 36. Several planet gears 42—three are depicted—are mounted to a planet carrier 44 and are engaged with and rotate around the sun gear 40. A ring gear 46 is engaged with and rotates around the planet gears 42. This arrangement of gears allows for three different speeds to be generated, as is well known.

The hub 20 may include four sets of (non-brake) pawls, all of which transmit torque in the forward/drive/clockwise direction D. The pawls are used to engage and disengage various components from the drive path as will be explained briefly herein. It will be understood that the exact drive path and components set out herein are exemplary in nature—other suitable arrangements of components would also serve to provide the same results as the instant example, as is evidenced by numerous other internal gear hubs with multiple speed capabilities having alternative drive paths compared to the hub illustrated herein.

Of the above-noted four sets of pawls, two sets are fixed and two sets are able to be actively engaged or disengaged. A first set of fixed pawls is mounted on the driver 24, and may be referred to as the driver pawls 48. The driver pawls 48 function to transmit torque from the driver 24 to the ring gear 46.

A second set of fixed pawls is mounted on a roller guide ring 52, and may be referred to as the roller guide ring pawls 50. The roller guide ring 52 is positioned near the end of the hub shell 22 opposite the driver 24, and about a cylindrical, toothed extension 44′ of the planet carrier 44. The roller guide ring pawls 50 function to transmit torque to the hub shell 22.

A first set of switchable pawls is mounted on the ring gear 46, and may be referred to as the ring gear pawls 54. The default state of the ring gear pawls 54 is to be in engagement with the hub shell 22, and each of the ring gear pawls are held in this state by a spring, as is well known, or other biasing means. The ring gear pawls 54 may be disengaged from the hub shell 22, or permitted to engage therewith, by action of a ring gear shift bushing 56, which when pushed against the ring gear pawls retracts them away from engagement with the hub shell. Conversely, when the ring gear shift bushing 56 is removed from contact with the ring gear pawls 54, the pawls are not prevented from responding to the force of the pawl springs, and thus, the springs urge the ring gear pawls into contact with hub shell 22.

The ring gear shift bushing 56 is positioned about the axle 36, and configured to be responsive to changes in the state of the shifting mechanism 30. The ring gear shift bushing 56 has two positions. The default position (see FIG. 3 c) is where the ring gear shift bushing 56 is pushed against the ring gear pawls 54, which holds the ring gear pawls out of engagement with the hub shell 22. The ring gear shift bushing 56 is held against the ring gear pawls 54 by a shift bushing spring 58. This spring 58 exerts enough force to overcome the spring force exerted by the pawl springs which hold the ring gear pawls 54 in engagement with the hub shell 22. The second position for the ring gear shift bushing 56 is to be pushed away from the ring gear pawls 54, allowing the pawls to engage with the hub shell 22.

The position of the ring gear shift bushing 56 is controlled by the position of a cam 60 that forms a part of the shifting mechanism 30. The structure and function of the cam 60 and shifting mechanism 30 are discussed in detail below.

The second set of switchable pawls, which may be referred to as planet carrier pawls 62, is mounted on a pawl carrier 64. The pawl carrier 64 is positioned about the axle 36, between the shifting mechanism 30 and the planet carrier 44. The pawl carrier 64 also guides the ring gear shift bushing 56. The default state of the planet carrier pawls 62 is to be in engagement with the planet carrier 44, which are held in this default state by pawl springs, as is well known. The planet carrier pawls 62 may be disengaged from the planet carrier by a planet carrier shift bushing 66 that is positioned about the axle and extends between the cam 60 of the shifting mechanism 30 and the planet carrier pawls. When the planet carrier shift bushing 66 is pushed against the planet carrier pawls 62 by the cam 60, the pawls are retracted away from the planet carrier 44 and prevented from engaging the planet carrier.

The planet carrier shift bushing 66 has two positions. The default position (see FIG. 3 c) is to be pushed against the pawls 62, which holds them out of engagement with the planet carrier 44. The planet carrier shift bushing 66 may be held in this position by a spring 68. This planet carrier shift bushing spring 68 exerts enough force to overcome the force exerted by conventional pawl springs, or the like, that hold the pawls 62 in engagement with the planet carrier 44. The second position for the planet carrier shift bushing 66 is to be pushed away from the pawls 62, allowing them to engage with the planet carrier 44. The position of the planet carrier shift bushing 66 is controlled by the position of the cam 60.

This basic arrangement of four sets of drive pawls, plus the one set of pawls used to engage the brake, is identical to that used in the SRAM® “i-Motion 3” hub. Speed selection is governed by the position of cam 60, which is located concentrically about the axle 36, and is permitted to rotate about and move axially along the axle. The cam 60 is generally cylindrical with a cam profile 70, (see FIG. 12) which may be a stepped or cam feature or face on an end face of the cam, wherein each step or feature determines the indexed position of the cam, and a resultant selected speed of the hub.

The cam 60 is operatively in communication with the driver 24 by a first clutch 72 which includes a spring 74 disposed interior to the driver 24, and a splined sleeve 76 disposed between the cam and the spring. This first clutch 72 causes the cam 60 to rotate with the driver 24 in both directions (forward and reverse depending upon the rotational direction of the driver) and allows the driver to rotate freely when the cam is stationary. The splined sleeve 76 is configured to couple the cam 60 to the driver 24 rotationally, but permits movement axially along the axle 36.

The cam 60 locates against a cam follower 78, which may be disposed in a recess 80 formed in the axle 36. In one embodiment, the cam follower 78 is movably received by the axle 36. For example, the cam follower 78 may be pivotally attached to the axle such that the cam follower can pivot radially inwardly and outwardly. Alternatively, the cam follower 78 can be disposed in the recess 80 such that it is permitted to move radially inwardly and outwardly without pivoting.

The cam follower 78 is fixed rotationally with respect to the axle 36 and biased in a radially outward direction. As the cam 60 rotates, the face or cam profile 70 bears against the cam follower 78, which may cause the cam to move axially along the axle 36.

The profile 70 on the cam 60 dictates the positions of the cam, each position corresponding to a different speed selection of the hub 20, by causing different combination of states of the four sets of drive pawls. When the cam follower 78 locates against the cam profile 70 to produce one of these states/positions, a different speed is selected.

The cam follower 78 has two positions. The default position is to be in engagement with the cam 60, and the cam follower 78 is held in this engaged position by a follower spring 82, or the like, disposed in the recess 80 between the axle 36 and the cam follower. The second position is for the cam follower 78 to be retracted and thus taken out of engagement with the cam 60. This second, non-engaged position occurs when a reset member 84 rotates far enough to engage with the cam follower 78 and urge it out of engagement with the cam 60 by causing the follower to be urged into the recess 80. The retraction of the cam follower 78 is produced when interacting with a cam reset profile in the form of an interior face 102 on the reset member 84 that functions to push the cam follower 78 into the recess 80 of the axle 36. This disengages the cam follower 78 from the cam 60.

The reset member 84 is operatively responsive to the driver 24 through a second clutch 88, which causes the reset member to rotate with the driver and also to slip when needed in the same fashion as the first clutch 72. The rotation of the reset member 84 may be limited to a fixed or predetermined angle by a reset limit washer 90, which is keyed to the axle 36 and thus is rotationally fixed with respect to the axle. The reset limit washer 90 has tangs 92 that engage with rotational slots 94 on the reset member 84. These slots 94 allow the reset member 84 to rotate by a fixed angle. Once the limit of rotation is reached the second clutch 88 will slip.

Shown best in FIG. 13, the reset member 84 may be in the form of a ring-shaped member positioned about the axle with an interior opening 98 defined by an interior wall or surface defining a first radius 100, and further including an interior face 102 that leads to a second part of the interior opening having a smaller radius curvature 104 of the interior opening. The reset member 84 is disposed about the axle 36 and over a part of the cam follower 78. The cam follower 78 has a radially outwardly oriented face 106 that may be angled or otherwise configured to cooperate with the interior face 102 of the reset member 84. In a state corresponding to forward rotation D of the driver 24, the cam 60, and the reset member 84, the first radius 100 of the interior opening 98 is positioned over the cam follower 78, and thus the reset member is spaced from and disengaged from the cam follower. In this state the reset member 84 is not acting upon the cam follower 78. When the reset member 84 is rotated back a predetermined number of degrees (see B in FIG. 2, which is, for example, more reverse rotation than to cause a shift operation, (see A in FIG. 2)) via a change of position/state of the cam 60, and somewhat less rotation than to create a braking operation, (see C in FIG. 2), the interior face 102 and then the lesser, second radius 104 of the reset member 84 comes into engagement with the cam follower 78, causing the cam follower to be depressed into the recess 80 and disengaging from the cam 60. It will be understood that the pitch of the reset member 84 is therefore set at an amount to operate the cam follower 78 before the brake mechanism is operated. The disengagement of the cam follower 78 from the cam 60 permits the cam to axially be urged by spring 58 into an initial state corresponding to a first/initial gear setting.

Cycle of Operation:

The default, starting, home, or initial position for the hub 20 and shifting system 30 will be understood to mean a state of the mechanism of the hub when in the lowest initial gear (first gear). The initial position is best shown in FIG. 3 a-c. In this condition, the planet carrier pawls 62 and the ring gear pawls 54 are held out of engagement. When torque is applied to the driver 24 in the forward/drive/clockwise direction, the driver pawls 48 engage with the ring gear 46, which in turn engages the planet gears 42. The planet gears 42, which are connected to the planet carrier 44, engage with the roller guide ring 52. The roller guide ring pawls 50 engage with the hub shell 22, which in turn rotates the wheel in an under-drive condition. In this state, the ring gear 46 serves as the input from the driver 24 and the planet carrier 44 serves as the output to the hub shell through the roller guide ring 52.

In this under-drive condition, the cam 60 is in the default position and is located axially against the reset member 84 and rotationally against the cam follower 78. The cam 60 is held in this position axially by the planet carrier shift spring 68 and rotationally by the torque and friction applied by the first clutch 72. The reset member 84 is located rotationally against the reset limit washer 90 and is held in this position by the torque and friction applied by the second clutch 88.

When torque is applied to the driver 24 in the reverse/braking/counterclockwise direction, the first clutch 72 rotates the cam 60 causing the cam to move axially along the axle 36 as the cam profile 70 bears against the follower 78. As the cam 60 moves it pushes the planet carrier shift bushing 66 along the axle 36, causing it to disengage with the planet carrier pawls 62, and allows the planet carrier pawls to engage with the planet carrier 44. Once the cam 60 locates against the cam follower 78 in the second position (corresponding to second gear), the planet carrier shift bushing 66 is held out of engagement with the planet carrier pawls 62. In this condition, when torque is applied to the driver 24 in the forward/drive/clockwise direction D the driver engages with the planet carrier 44 via the coupler 96, the pawl carrier 64, and the planet carrier pawls 62. The planet carrier 44 engages with the roller guide ring 52 as before, but in this state or condition the drive path bypasses the planet gears 42. This causes a 1:1 drive condition and may be considered a second gear state or second gear.

If, in the above example, at the point where the shift is achieved (see A in FIG. 2), torque continues to be applied in the reverse direction (see B in FIG. 2), the reset member 84 engages with the cam follower 78 and urges the cam follower into the recess 80, and out of engagement with the cam 60. This causes the cam 60 to be pushed back into the default position by the planet carrier shift spring 68. If torque is then applied to the driver 24 in the forward direction D, then the drive path will be as in the default state described above. This illustrates the reset feature of the hub. This operation of the reset feature is also shown in FIGS. 14 and 15.

If, at the point where the reset is achieved, torque continues to be applied to the driver 24 in the reverse condition, the control bushing 108 may be rotated far enough to uncover the brake pawls 38 (see C in FIG. 2), which then engage with the ring gear 46. The ring gear 46 then drives the roller guide ring 52, through the planet gears 42 and planet carrier 44, which activates the brake.

If torque is applied in the reverse condition when the cam 60 is located against the cam follower 78 in the second gear (1:1) position, the cam rotates against the cam follower and moves laterally, axially along the axle 36. When the cam moves from second gear position into the third (3^(rd)) gear position it pushes the ring gear shift bushing 56 out of engagement with the ring gear pawls 54 allowing the ring gear pawls to engage with the hub shell 22. In this condition, when torque is applied to the driver 24 in the forward direction, the driver engages with the planet carrier 44 via the coupler 96, the pawl carrier 64, and the planet carrier pawls 62. The planet carrier 44 rotates the planet gears 42 around the sun gear 40 on the axle 36, which in turn transfers torque to the ring gear 46. The hub shell 22 will now rotate in an overdrive condition.

If, at the shift point the driver 24 were to continue rotating backwards, then the cam 60 would reset as previously described. To return to first gear from third gear, the driver 24 must be rotated back far enough for the cam to reset. In one embodiment, the amount of backward rotation to return the system to first gear is about 100 degrees of rotation (see B in FIG. 2).

While this invention has been described by reference to a particular embodiment, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiment, but that it have the full scope permitted by the language of the following claims. 

1. A hub for a pedal-driven vehicle, comprising; a fixed axle, a planetary gear mechanism arranged about the fixed axle, the planetary gear mechanism operable to produce an initial gear ratio and at least one other gear ratio; a driver arranged about the fixed axle and rotatable in a drive direction and a non-drive direction; and a shifting mechanism coupled to the driver, the shifting mechanism including a cam, a reset member, and a cam follower engageable with the cam and the reset member, the cam including a profile and being axially movable to select between the initial gear ratio and the at least one other gear ratio of the hub, the cam follower configured to engage the profile of the cam to axially position the cam, and the reset member configured to disengage the cam follower from the cam in response to a rotational movement of the driver in the non-drive direction and permit the cam to move axially to reset to the initial gear ratio.
 2. The hub of claim 1, wherein the cam is biased into an initial position that produces the initial gear ratio.
 3. The hub of claim 2, wherein the reset member is configured to permit the cam to reset to the initial position in response to the rotational movement of the driver an amount greater than required to produce a change in gear ratio but less than required to produce braking.
 4. The hub of claim 1, wherein the shifting mechanism is coupled to the driver through a clutch.
 5. The hub of claim 4, wherein both the cam and the reset member is coupled to the driver through a clutch.
 6. The hub of claim 5, wherein the cam is coupled to the driver through a first clutch and the reset member is coupled to the driver through a second clutch.
 7. The hub of claim 6, wherein the first clutch and the second clutch each comprise a clutch spring.
 8. The hub of claim 1, wherein the profile of the cam is an indexed profile positioned on an end of the cam.
 9. The hub of claim 8, wherein the cam follower is configured to engage the indexed profile of the cam.
 10. The hub of claim 1, wherein the cam follower is biased to engage the cam.
 11. The hub of claim 1, wherein the cam follower is disposed on the axle.
 12. The hub of claim 11, wherein the cam follower is pivotally received by the axle.
 13. The hub of claim 1, wherein the axle has a recess in which the cam follower is disposed.
 14. The hub of claim 13, wherein the cam follower is biased away from the axle to project from the recess so as to engage the cam.
 15. The hub of claim 1, wherein the cam follower has a face configured to engage the reset member.
 16. The hub of claim 15, wherein the reset member is annular.
 17. The hub of claim 16, wherein the reset member is arranged about the cam follower.
 18. The hub of claim 17, wherein the reset member is configured to engage the face of the cam follower.
 19. The hub of claim 16, wherein the reset member has an interior opening that interiorly receives the cam follower.
 20. The hub of claim 19, wherein the interior opening has an interior surface that defines a first radius and a second radius, the first radius being greater than the second radius.
 21. The hub of claim 20, wherein the first radius does not disengage the cam follower and the second radius disengages the cam follower from the cam when the second radius is engaged with the face of the cam follower.
 22. The hub of claim 21, wherein the reset member includes an interior face extending between the first radius and the second radius of the interior surface.
 23. The hub of claim 22, wherein the interior face of the reset member is configured to engage with the face of the cam follower.
 24. The hub of claim 1, wherein the reset member is configured to permit the cam to reset to an initial position corresponding to the initial gear ratio in response to the rotational movement of the driver a predetermined amount greater than required to produce a change in gear ratio but less than required to produce braking.
 25. The hub of claim 1, wherein the reset member is configured to permit the cam to reset to an initial position corresponding to the initial gear ratio in response to a backpedaling movement a predetermined amount greater than required to produce a change in gear ratio but less than required to produce braking. 